Homemade Ultra-Cal 30

MoviesColin

Well-Known Member
Just a little tip I thought I'd share.

A lot of noobies or hobbyists use Plaster of Paris to create a stone mold for latex costume pieces. This is cheap and works great for most single-sided molds. But for masks or molds with a lot of curves it becomes a problem since the plaster chips and can break and fracture.

Ultra-Cal 30 is the "standard" and is a super strong "version" of plaster - industry professionals use it all the time.

Since it's heavy, it costs an arm and a leg to ship, and to me, that's a big deal since I have no local stores that carry the product.

Per the MSDS sheet for Ultra-Cal, you can cheaply make a version of it to use yourself. I did this, and I use it all the time for the added strength. This allows me to be more creative with sculpts and molds and also use less materials since it's stronger - instead of an inch thick mold, you can have a 1/4 inch mold that will be just as strong.

The ingredients:

Plaster of Paris
"Quickrete" Fast-Cure Cement
Gram scale

The ratio is 80% Plaster to 20% Cement, by weight.

For my recent mold (Wolf Predator chest armor) I mixed 650 grams of Plaster with 150 grams of Cement. My mold is around a 1/4" thick and came off of the mannequin with no fuss, no cracks, and no problems. The mold is strong and looks great.

I'd like to note that the MSDS sheet says: "85% Plaster, 10% Portland Cement, 5% Silica." Since I'm not sure exactly what Silica is or where to get it, I didn't bother with it and used the cement and plaster only.

The cement and plaster should both be powders. I mixed the powders together in one bucket and added the water (2 parts powder - 1 part water). The result looked, felt, and smelled like Ultra-Cal 30.

Just thought I would share. 
 
I've used a mix similar to this in the past, but did use the silica (sand).  We used type II portland, because it's what we had on hand.  If I were to do it again I would go with the type III because of how finer it's ground.  It wasn't bad, but the sand (which adds most of the strength to portland) leaves it pretty rough, especially if you can't get to it to trowel it smooth.  I never thought about using this for molding, but it seems like it would work better than POP alone.  I'm lucky in that I have a supplier for UC-30 about 1/2 mile from my house :)  Good tip, thanks for passing it on.

Brian 
 
Great tip man! It's always good to hear of new ways that are effective and better on the wallet!
 
MEANGENE83 said:
Dont smell ultracal ! Its bad for your health!

:p Good tip brother, been a long time - glad to see you are back
Haha thanks Gene!

I always take a break from this stuff for a long time and then randomly get back into it. It's fun but very frustrating. As my wallet never allowed UC30, molding was especially frustrating. 

Glad to be back!
 
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